Dover HEIL POWERTRAK COMMERCIAL PLUS Service Manual
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Dover HEIL POWERTRAK COMMERCIAL PLUS Service Manual

Dover HEIL POWERTRAK COMMERCIAL PLUS Service Manual

High-compaction tag axle rear loader
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®
POWERTRAK
COMMERCIAL PLUS
HIGH-COMPACTION TAG AXLE REAR LOADER
SERVICE MANUAL
ISSUED JULY 2020
TP1PTCP-SM-0720
© 2020 Heil Environmental
.

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Summary of Contents for Dover HEIL POWERTRAK COMMERCIAL PLUS

  • Page 1 ® POWERTRAK COMMERCIAL PLUS HIGH-COMPACTION TAG AXLE REAR LOADER SERVICE MANUAL ISSUED JULY 2020 TP1PTCP-SM-0720 © 2020 Heil Environmental...
  • Page 2 WARNING IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS MANUAL FOR FUTURE REFERENCE IMPORTANT SAFETY NOTICE Proper service and repair are important to the safe, reliable operation of Heil Co.’s products.

  • Page 3: Table Of Contents

    ® POWERTRAK COMMERCIAL PLUS TABLE OF CONTENTS General Information Introduction ......................................4 Service/Parts Assistance ......................................5 Recommended Spare Parts ......................................6 Electronic Parts Catalog (EPC) ......................................7 Hazard Symbols and Definitions ......................................10 Lock-Out/Tag-Out Procedures ......................................14 Storing Refuse in Container ......................................15 Maintenance/Lubrication Information ......................................15 Winch Gear Oil ......................................15 Grease Lubrication Recommendation ......................................15...
  • Page 4 ® POWERTRAK COMMERCIAL PLUS TABLE OF CONTENTS Cold Weather Warmup Procedure ......................................59 Preparing the Unit to Check the Oil Level ......................................60 Check Oil Level ......................................61 When to Change Oil Filter Element ......................................61 Change Hydraulic Oil Filter ......................................61 Drain and Clean the Hydraulic Oil Tank ......................................62 Purge the Hydraulic System ......................................63...
  • Page 5 ® POWERTRAK COMMERCIAL PLUS ® POWERTRAK COMMERCIAL PLUS HIGH-COMPACTION TAG AXLE REAR LOADER SERVICE MANUAL ISSUED JULY 2020 TP1PTCP-SM-0720 Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A.
  • Page 6 ® POWERTRAK COMMERCIAL PLUS NOTES Issued July 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.

  • Page 7: General Information

    ® POWERTRAK COMMERCIAL PLUS General Information SECTION 1 GENERAL INFORMATION Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. General Information...

  • Page 8: Introduction

    ® POWERTRAK COMMERCIAL PLUS General Information INTRODUCTION The following sections are a guide for maintenance and service of the Heil unit. The sections cover preventive maintenance, adjustment, and troubleshooting hints. Before performing maintenance, check the work area carefully to find all the hazards present and make sure all necessary safeguards or safety devices are used to protect all persons and equipment involved.

  • Page 9: Service/Parts Assistance

    ® POWERTRAK COMMERCIAL PLUS General Information SERVICE/PARTS ASSISTANCE Assistance in troubleshooting repair and service is available by contacting the authorized Heil Dealer in your area. Parts are available at your Heil Dealer or through Heil. Heil personnel are trained to give prompt, professional assistance. ALWAYS give the unit serial number in all correspondence relating to the equipment.

  • Page 10: Recommended Spare Parts

    ® POWERTRAK COMMERCIAL PLUS General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION BODY AND TAILGATE ASSEMBLIES 022-3509 SEAL, TAILGATE, 240" 028-0479 SHOE, SLIDE 028-0358 SHOE, BLOCK CAST 204-8413 BEARING, THRUST 204-8414 BOLT, EYE 019-1242 SPRING, 1” OD X 6” 048-7263 PIN, BLADE PIVOT 048-6268 PIN, CYLINDER BLADE...

  • Page 11: Electronic Parts Catalog (Epc)

    ® POWERTRAK COMMERCIAL PLUS General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION 108-6752 RELAY, WEATHER PROOF CONTROLS 070-1391 HANDLE GRIP 013-5014 LEVER 108-2280 RUBBER BOOT, 4000 108-8464 SWITCH, TOGGLE SPST 108-8467 SWITCH, PUSH BUTTON, NO W/CONNECTOR 108-8444-001 CAP, ROCKER, PUMP ELECTRONIC PARTS CATALOG (EPC) The Parts Central EPC includes electronic versions of the Heil Parts Manuals, specific to a Customer’s truck configuration and options.
  • Page 12 ® POWERTRAK COMMERCIAL PLUS General Information Search by Part Keyword(s) or Part Number in Body Serial Number After login, you will land on the User Dashboard. At the top right of the Dashboard, there will be two search fields, as shown in the image below.
  • Page 13 ® POWERTRAK COMMERCIAL PLUS General Information Search by Body Serial Number If you want to view an entire parts catalog for a particular Heil unit, you can search by only the Heil Body Serial Number, leaving the Keyword(s) / Part Number field blank. The search result will then be the Body Serial Number-specific parts catalog with familiar catalog sections that you can browse.

  • Page 14: Hazard Symbols And Definitions

    ® POWERTRAK COMMERCIAL PLUS General Information PRECAUTIONARY STATEMENTS Listed below are the definitions for the various levels of hazards. It is important that the operators of this equipment and people who service units read and understand all warnings as they relate to this equipment operation. DANGER –...
  • Page 15 ® POWERTRAK COMMERCIAL PLUS General Information DANGER The packer and crusher panels are dangerous. They can cause death or serious injury if a person is inside the hopper. Make sure no one is inside the hopper before you begin a packer or crusher function. Put the unit in the Lock-Out/Tag-Out mode if it is necessary to enter the hopper area.
  • Page 16 ® POWERTRAK COMMERCIAL PLUS General Information WARNING Clear all people of the area before you lift a refuse container. Make sure the refuse is secure in the refuse container before you lift the container. Loose refuse can fall and cause death or serious injury. WARNING The hydraulic fluid can be under pressure and can spray while you open the connection.
  • Page 17 ® POWERTRAK COMMERCIAL PLUS General Information NOTICE Grabbing a refuse container with too much pressure can damage the container. The container can become unusable. Use enough pressure with the grabber to raise the container with the lift arm and not damage the container. NOTICE Always use your employer’s Lock-Out/Tag-Out procedures.

  • Page 18: Lock-Out/Tag-Out Procedures

    ® POWERTRAK COMMERCIAL PLUS General Information LOCK-OUT/TAG-OUT PROCEDURES NOTICE Always use your employer’s Lock-Out/Tag-Out procedures. If your employer does not have Lock-Out/Tag-Out procedures, use the procedures that follow. Contact your supervisor or Heil Technical Service if you have any questions about Lock- Out/Tag-Out procedures.

  • Page 19: Storing Refuse In Container

    ® POWERTRAK COMMERCIAL PLUS General Information STORING REFUSE IN THE BODY Heil does not recommend storing refuse in the body overnight. The different types of debris and corrosive elements usually collected can cause severe corrosion inside the body decreasing the life of your body. This corrosion can affect unloading and decrease the structural life of the body.

  • Page 20: Standard Torque Data For Nuts And Bolts

    ® POWERTRAK COMMERCIAL PLUS General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS The following recommended torque data is for use as a general guideline. Recommended torque, in foot pounds, for all Standard Application nuts and bolts provided in the following table. NOTICE Torque specifications on a drawing override torque values in the Standard Torque Data for Nuts and Bolts Table.
  • Page 21 ® POWERTRAK COMMERCIAL PLUS General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value...
  • Page 22 ® POWERTRAK COMMERCIAL PLUS General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value...
  • Page 23 ® POWERTRAK COMMERCIAL PLUS General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value...

  • Page 24: Bolt Type Identification Chart

    ® POWERTRAK COMMERCIAL PLUS General Information BOLT TYPE IDENTIFICATION CHART S.A.E. Bolt Head Description Type Grade Marking** No radial lines. 1 or 2 Low or medium carbon steel not heat treated. NOT USED, replace with same grade bolt. Three radial lines. Quenched and tempered medium carbon steel.

  • Page 25: Torque For Hydraulic Tubes And Fittings

    ® POWERTRAK COMMERCIAL PLUS General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS FLAT FACE ORFS FITTINGS SET WRENCH TO NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 1/4" 21 ft-lbs. 250 in-lbs. 3/8" 33.5 ft-lbs. 400 in-lbs. 1/2" 50 ft-lbs. 600 in-lbs.
  • Page 26 ® POWERTRAK COMMERCIAL PLUS General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) 37 DEGREE FLARE (JIC) FITTINGS SET WRENCH TO NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 1/8" 6.5 ft-lbs. 80 in-lbs. 3/16" 9 ft-lbs. 110 in-lbs. 1/4"...
  • Page 27 ® POWERTRAK COMMERCIAL PLUS General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) FROM SAE J2593 TABLE 7 (STEEL) SET WRENCH TO BOSS (ORB) NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 3/16" 9 ft-lbs. 110 in-lbs. 1/4" 16.5 ft-lbs. 200 in-lbs.
  • Page 28 ® POWERTRAK COMMERCIAL PLUS General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) Figure 4. Torque for Hydraulic Tubes and Fittings SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 61) SET WRENCH TO NOMINAL TUBE BOLT SIZE BOLT TORQUE [FT- BOLT TORQUE [IN-LBS] ALUMINUM FT- LBS] LBS [IN-LBS]...
  • Page 29 ® POWERTRAK COMMERCIAL PLUS General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 62) SET WRENCH TO NOMINAL BOLT SIZE BOLT TORQUE [FT- BOLT TORQUE [IN-LBS] ALUMINUM FT-LBS [IN- TUBE OD LBS] LBS] 1/2" 5/16-18 x 1.25 17 ft-lbs.

  • Page 30: Cold Weather Warmup Procedure

    ® POWERTRAK COMMERCIAL PLUS General Information COLD WEATHER WARMUP PROCEDURE When ambient air temperature is cold (below 0 degrees F), it is necessary to warm up the unit’s hydraulic oil before you start your daily route operation, check the oil level, or adjust hydraulic pressure settings. The hydraulic oil is sufficiently warmed when the temperature is between 120°...

  • Page 31: Proximity Switch Troubleshooting

    ® POWERTRAK COMMERCIAL PLUS General Information PROXIMITY SWITCH TROUBLESHOOTING When one or more of a unit’s functions do not operate properly and there are proximity switches in the circuits of the unit for these functions, refer to the following table as a guide to find the problem(s). NOTICE Heil proximity switches have a Light Emitting Diode (LED) on the switch to indicate that the switch is sensing metal.
  • Page 32 ® POWERTRAK COMMERCIAL PLUS General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Issued July 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.
  • Page 33 ® POWERTRAK COMMERCIAL PLUS General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. General Information...
  • Page 34 ® POWERTRAK COMMERCIAL PLUS General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Issued July 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.

  • Page 35: Decals On The Unit

    ® POWERTRAK COMMERCIAL PLUS General Information DECALS ON THE UNIT Make sure you can read all hazard and instruction decals. Clean decals if you cannot read the words. See for directions on cleaning decals. Replace any decal that is damaged, missing, or is not readable. When you replace a part that has a decal, make sure a new decal is installed on the new part.
  • Page 36 ® POWERTRAK COMMERCIAL PLUS General Information DECAL CARE (CONTINUED) Figure 5. Recommended Technique Figure 6. Incorrect Technique Issued July 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.

  • Page 37: Hydraulic Symbols

    ® POWERTRAK COMMERCIAL PLUS General Information HYDRAULIC SYMBOLS Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. General Information...
  • Page 38 ® POWERTRAK COMMERCIAL PLUS General Information HYDRAULIC SYMBOLS (CONTINUED) Issued July 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.

  • Page 39: Electrical Symbols

    ® POWERTRAK COMMERCIAL PLUS General Information ELECTRICAL SYMBOLS Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. General Information...
  • Page 40 ® POWERTRAK COMMERCIAL PLUS NOTES Issued July 2020 Copyright 2020, Heil Environmental Pumps Printed in the U.S.A.
  • Page 41 ® POWERTRAK COMMERCIAL PLUS Pumps SECTION 2 PUMPS Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Pumps...

  • Page 42: Hydraulic Pump Control

    ® POWERTRAK COMMERCIAL PLUS Pumps HYDRAULIC DRIVE CONTROL There are multiple hydraulic drive configurations available on the 2020 Rear End Loader. Each achieves the same goal utilizing different mechanisms and modes of operation. 1. Clutch Shift PTO Listed in the display as Cab Controller Output, OUT02 p16 – PTO Sol. a.
  • Page 43 ® POWERTRAK COMMERCIAL PLUS Pumps HYDRAULIC DRIVE CONTROL (CONTINUED) b. Constant Drive PTO or Crankshaft Driven Option Config Clutch Shift PTO, [OFF] Operation - ON with System Enable, governed by the following EOS parameters. Maximum Engine Speed for PTO Engagement: 1000 RPM 3.

  • Page 44: Tandem O.i.g.a.i. Pump

    ® POWERTRAK COMMERCIAL PLUS Pumps TANDEM O.I.G.A.I. PUMP Front Loaders, Rear Loaders, Recycle 2000, and Liberty Figure 7. Tandem O.I.G.A.I. Pump This is the Hydraulic Controls Operate-In-Gear-At-Idle (OIGAI) System. The pump section (pump 1) closest to the input shaft operates the lift and shuts off first. The pump section (pump 2) farthest from the input shaft operates the packer and stays on at higher RPMs.

  • Page 45: Tandem Vane Pump O.i.g.a.i. Hydraulic System Troubleshooting

    ® POWERTRAK COMMERCIAL PLUS Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING The Operate-in-Gear-at-Idle (OIGAI) system is designed to perform the loading operations at standard idle speed. It is comprised of two major components, the monoblock tandem vane pump and attached unloader valve assembly. On the OIGAI Rear End Loader (REL) systems the P1 closest to the pump input shaft while the P2 farthest from the input shaft supplies flow to the complete hydraulic systems.
  • Page 46 ® POWERTRAK COMMERCIAL PLUS Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING (CONTINUED) NOTICE If flow is present check the main relief valves for proper adjustment and operation. Figure 9. Issued July 2020 Copyright 2020, Heil Environmental Pumps Printed in the U.S.A.

  • Page 47: Body And Tailgate

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate SECTION 3 BODY AND TAILGATE Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Body and Tailgate...

  • Page 48: Specifications

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate SPECIFICATIONS A. Body Hydraulic Oil Tank ............................40.6 Gal. Hydraulic Oil System Capacity ..........................Gal. Hydraulic In-Tank Oil Filter (Units thru June 2004) ................... 7-Micron Hydraulic In-Tank Oil Filter (Units July 2004 & After) ..................5-Micron Hydraulic In-Tank Oil Filter (Units after May 2006) ....................

  • Page 49: Nomenclature

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate NOMENCLATURE Figure 10. Nomenclature Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Body and Tailgate...

  • Page 50: Tailgate Nomenclature

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate TAILGATE NOMENCLATURE Figure 11. Tailgate Nomenclature Issued July 2020 Copyright 2020, Heil Environmental Body and Tailgate Printed in the U.S.A.

  • Page 51: Tailgate Valve

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate TAILGATE VALVE The packing mechanism is controlled by two levers at the right rear corner of the tailgate. These levers control the upper panel and the lower panel. Refer to the operator’s manual for correct operation of these two levers. The upper and lower panel functions can be operated independently by engaging one lever at a time.

  • Page 52: Air Supply Kits Pneumatic Diagrams

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate AIR SUPPLY KITS PNEUMATIC DIAGRAMS Figure 13. Air Supply Kits Pneumatic Diagram Issued July 2020 Copyright 2020, Heil Environmental Body and Tailgate Printed in the U.S.A.

  • Page 53: Po Check/Dump Combination And Tailgate Controls Valves

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate PO CHECK/DUMP COMBINATION AND TAILGATE CONTROLS VALVES Shown below are the po check/dump combination and tailgate control valves. Figure 14. Control Valves Viewed from Tailgate Looking Up AUXILIARY VALVE SECTIONS Figure 15. Clean Areas for Auxiliary Valve Sections Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A.

  • Page 54: Tailgate Support Props

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate TAILGATE SUPPORT PROPS Figure 16. Issued July 2020 Copyright 2020, Heil Environmental Body and Tailgate Printed in the U.S.A.

  • Page 55: Turnbuckle Clamps / Access Cover

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate TURNBUCKLE CLAMPS / ACCESS COVER Turnbuckle clamps are located on both sides of the unit and are used to keep the tailgate locked to the body. These clamps should never be opened (unscrewed) unless servicing the unit or before emptying the body, to be able to raise the tailgate.

  • Page 56: Welding And Electronic Devices / Electrical Lubricants

    ® POWERTRAK COMMERCIAL PLUS Body and Tailgate WELDING AND ELECTRONIC DEVICES / ELECTRICAL LUBRICANTS proximity switches complete the following procedures. WARNING Never weld on a compressed natural gas vehicle unless the compressed natural gas fuel system has been purged with inert gas.

  • Page 57: Maintenance And Adjustment

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment SECTION 4 MAINTENANCE AND ADJUSTMENT Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Maintenance and Adjustment...

  • Page 58: Body Daily Checklist

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment BODY DAILY CHECKLIST Make sure you perform a daily check of the unit. Refer to the Operator’s Manual for the Daily Checklist. Many checks in the Daily Checklist are maintenance related, such as checking tire pressures and hoses for wear and damage. DAILY CHECKLIST MAINTENANCE ITEMS Item Required Action...

  • Page 59: Body Preventive Maintenance Chart

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART Preventive maintenance must be performed to ensure the safe and reliable operation of your unit. Use the chart below as a guideline for when essential items should checked and serviced. Severe use or adverse conditions may require more frequent maintenance.
  • Page 60 ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE spline PTOs such as the Chelsea 890/897 series. Lubricate as shown on Body Lube Grease Fittings Chart. Inspect body undercoating and repair Body Undercoating as necessary.

  • Page 61: Packer/Ejector Cylinders Preventive Maintenance

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment PACKER/EJECTOR CYLINDERS PREVENTIVE MAINTENANCE It is critical to follow the guidelines of the Body Preventive Maintenance Chart and Body Lubrication Guide found in this section of this Service Manual and the Body Lubrication Guide decal on the unit. Failure to follow stated routine preventive maintenance can lead to premature cylinder failure that is not covered by your warranty.

  • Page 62: Body Lubrication Guide

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment BODY LUBRICATION GUIDE Clean fittings before applying grease and always pump enough grease into joint to remove the old grease. Wipe off excess grease. Lubricate moveable mechanical parts without fittings every 60 days with non-detergent engine oil. Figure 18.

  • Page 63: Cold Weather Warmup Procedure

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment COLD WEATHER WARM-UP PROCEDURE When ambient air temperature is cold (below 0 degrees F), it is necessary to warm up the unit’s hydraulic oil before you start your daily route operation or to check the oil level. The hydraulic oil is sufficiently warmed when the temperature is between 120°...

  • Page 64: Preparing The Unit To Check The Oil Level

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment PREPARING THE UNIT TO CHECK THE OIL LEVEL Before checking the oil level or adding oil, make sure the unit is in the following position with all cylinders collapsed: Truck – on level ground Tailgate and Body –...

  • Page 65: Check Oil Level

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment CHECK OIL LEVEL Check the hydraulic oil level (after warning up the oil) daily or every eight (8) hours, whichever comes first. Fill as necessary. Important: Contamination is a hydraulic system’s worst enemy. Do not let dirt enter the system. Use a clean rag and remove dirt or other contamination around any system component before you disconnect or remove it.

  • Page 66: Drain And Clean The Hydraulic Oil Tank

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK Change the hydraulic oil when the oil sample shows to change it. Remember that almost all hydraulic system malfunctions can be traced to dirt in the fluid. When working with the hydraulic system, the hands, tools, working area and parts must be as clean as possible.

  • Page 67: Purge The Hydraulic System

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK (CONTINUED) NOTICE Before filling the tank be sure the funnel is clean and 200 mesh (or finer) screen is used to strain the hydraulic oil. 13.Fill tank with recommended oil, checking the sight gauge as you fill. Refer to Hydraulic Oil Specifications 14.Check the entire system to make sure all connections are tight and no leaks are found.

  • Page 68: Tailgate Valve Pressure Settings

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment TAILGATE VALVE PRESSURE SETTINGS The tailgate valve has some pressure settings that are adjustable. All valve pressure adjustments should be made with the engine running at the normal operating speed for the function that is being adjusted. Not all miniscule steps are listed below, only the main action steps are called out to simplify the procedure.
  • Page 69 ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment TAILGATE VALVE PRESSURE SETTINGS (CONTINUED) Figure 21. Hydraulic Detent B. Adjust the Upper Panel Hydraulic Detent NOTICE The upper panel has a hydraulic detent for down set @ 2400 PSI and mechanical detent for the up function and is adjusted mechanically.
  • Page 70 ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment TAILGATE VALVE PRESSURE SETTINGS (CONTINUED) 3. Turn adjustment screw of Valve “C” out of body 2 full turns (counter clockwise). 4. Turn adjustment screw of Valve “B” into the body 2 full turns (clockwise). 5.

  • Page 71: Underbody Valve (Main Relief)

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment UNDERBODY VALVE (MAIN RELIEF) Hydraulic oil must be at or near operating temperature. If not warm, see Cold Weather Warmup Procedure . Remove dirt and grease around main relief. NOTICE All adjustments must be made with throttle advance engaged. 1.

  • Page 72: Kick-Out Adjustment (Slide Up)

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment KICK-OUT ADJUSTMENT (SLIDE UP) The kick-out lever is on the inside of tailgate on the right hand side. Adjust as follows; 1. Adjust the linkage so it does not engage the slide cylinder. Loosen jam nuts (at both ends of the rod) and turn the adjusting rod clockwise to shorten (to kick-out sooner) or counterclockwise to lengthen (to kick-out later) the rod.

  • Page 73: Tailgate Control Lever Alignment

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment TAILGATE CONTROL LEVER ALIGNMENT 1. The Handles should be in line when in the neutral position and the outside cylinder in mid-stroke. 2. If out of alignment, loosen jam nuts on blade control adjusting rod. Turn rod clockwise to shorten or counterclockwise to lengthen.

  • Page 74: Blade Back-Off Relief Adjustment

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment BLADE BACK-OFF RELIEF ADJUSTMENT A relief is provided in the tailgate valve to allow the lower panel to back off slightly (2 to 5 inches of cylinder stroke) during the final stages of packing the load. If the cylinders back-off excessively (5 to 7 inches of cylinder stroke), the back-off relief needs to be adjusted or replaced.

  • Page 75: Slide Shoe Removal

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment SLIDE SHOE REMOVAL Figure 24. Illustration of Slide Shoe Cover Removed OPTIONAL WINCH OIL LEVEL CHECK PROCEDURE Check winch oil level every 2 months or 400 hours, whichever comes first. If low on oil, add AGMA Grade 7EP (140 wt.) gear oil.

  • Page 76: Cracked Weld Joints

    ® POWERTRAK COMMERCIAL PLUS Maintenance and Adjustment REPAIRING CRACKED WELD JOINTS Repair all cracked weld joints immediately after finding cracked weld joints. If you are unsure of the proper repair procedure, call Heil Technical Services at 866-310-4345. OIL LUBRICANT RECOMMENDATION Use only non-detergent engine oil to lubricate all moveable mechanical parts not furnished with grease fittings.

  • Page 77: Body Controller Hardware

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware SECTION 5 BODY CONTROLLER HARDWARE Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Body Controller Hardware...

  • Page 78: In-Cab Display

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware IN-CAB DISPLAY Issued July 2020 Copyright 2020, Heil Environmental Body Controller Hardware Printed in the U.S.A.

  • Page 79: In-Cab Display

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware IN-CAB DISPLAY ® Refer to the Heil PowerTrak operating the unit. The display also allows a qualified and authorized Service Technician to see detailed system information and make configuration changes based on option configuration. Status LED The Status LED on the bottom-right corner of the display indicates status of the display as described below.
  • Page 80 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CAB CONTROLLER INPUTS SCREEN This Cab Controller Inputs screen displays the status of Cab Controller inputs and parameters. INPUT PIN # DESCRIPTION FUNCTION IN00 PTO Pressure Sw. ON with PTO engaged IN01 Low Torque PSW. ON with O.A.I.
  • Page 81 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware BODY CONTROLLER INPUTS SCREEN This Body Controller Inputs screen displays the status of Body Controller inputs and parameters. INPUT PIN# DESCRIPTION FUNCTION IN00 Hyd. Press #1 Main body valve inlet pressure IN01 Hyd. Press #2 CV valve pressure IN02 Hyd.
  • Page 82 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware TAILGATE CONTROLLER INPUTS SCREEN This Tailgate Controller Inputs screen displays the status of Tailgate Controller inputs and parameters. INPUT PIN# DESCRIPTION FUNCTION IN00 Tipper Curb Side ON with cart tipper activated, curb side IN01 Tipper Street Side ON with cart tipper activated, street side...
  • Page 83 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CHASSIS VARIABLES (J1939) SCREEN This screen displays chassis variables which are received from the chassis J1939. Some variables are not available on all chassis, in which case the variable status will not update. On chassis where J1939 is not available, Engine RPM is derived from the alternator R Stator or tach.
  • Page 84 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CAB CONTROLLER OUTPUTS SCREEN This Cab Controller Outputs screen displays the status of Cab Controller outputs. OUTPUT PIN# DESCRIPTION FUNCTION OUT00 Spare Out OUT01 Spare Out OUT02 PTO Sol. Power to Clutch shift PTO solenoid OUT03 Pump 1 Sol.
  • Page 85 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware BODY CONTROLLER OUTPUTS SCREEN This Body Controller Outputs screen displays the status of Body Controller outputs. OUTPUT PIN# DESCRIPTION FUNCTION OUT00 Right Turn Light NOT USED, Power to mid body RH Turn lamp OUT01 Left Turn Light NOT USED, Power to mid body LH Turn lamp...
  • Page 86 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware TAILGATE CONTROLLER OUTPUTS SCREEN This Tailgate Controller Outputs screen displays the status of Tailgate Controller outputs. OUTPUT PIN# DESCRIPTION FUNCTION OUT00 Right Turn Light RH Multi-Function Strobe OUT01 Left Turn Light LH Multi-Function Strobe OUT02 Stop Light NOT USED, Power to Stop lamps...
  • Page 87 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware FAULT SCREENS Access fault screens from the Home screen by using the UP directional arrow. CRITICAL FAULTS SCREEN Critical faults result in disabled functions, allowing limited to no operation. These faults are displayed in the Home Screen Message Banner, which allows one message at a time based upon order of importance.
  • Page 88 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware SYSTEM FAULTS SCREEN Access this screen from the Critical Fault screen by using the LEFT directional arrow. System faults occur with the loss of a signal or, when a signal is out of the normal operating range. These faults are retained through a power cycle and once active will remain active until reset.
  • Page 89 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CONTROLLER FAULTS SCREEN Access this screen from the Critical Fault screen by using the RIGHT directional arrow. Controller faults occur with the following: Supply voltage to a controller is lost or low. A controller output has an error, short or open circuit etc. Loss of communications with or between two controllers.
  • Page 90 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware FAULT CAUSE Body, Output Error Error diagnostic on one or more outputs 00 thru 07 Body, Lost Comms w/ Controller lost comms with in-cab display. Display Body, Lost Comms w/ Controller lost comms with Body controller. Body Body, Lost Comms w/ Controller lost comms with Tailgate controller.
  • Page 91 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware PASSWORD PROTECTED SCREENS To access password protected screens press and hold the OK button for 3 seconds. This will switch the view to the password screen. Enter the password and press OK. PASSWORD PROTECTED SCREEN PASSWORD Maintenance 4321...
  • Page 92 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware OPTION CONFIG SCREEN The Option Config screen is used to configure the system. Press the OK button to turn the functions ON/OFF. Press ESC to exit screen. Clutch Shift PTO ON, enables the PTO Solenoid output and should be used when a Clutch shift PTO in installed. Additionally, the hydraulic pump may or may not be configured with a solenoid controlled manifold block.
  • Page 93 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware OPTION CONFIG SCREEN (CONTINUED) Multi-Function Strobe ON, enables a secondary use of the tailgate turn lamps. When not in use as turn signals, the lamps can be used as alternating strobe lights. Option Switches ON, enables two multiplexed body controller outputs to be used for optional functions.
  • Page 94 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware MAINTENANCE SCREEN Filter Change Reset, press OK button to reset Oil Change Reset, press OK button to reset Service Mode, press OK button to activate. Service mode is strictly intended to allow pump operation while servicing or troubleshooting the unit.

  • Page 95: Cortex Controller

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CORTEX CONTROLLER Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Body Controller Hardware...

  • Page 96: Programmable Controllers

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware PROGRAMMABLE CONTROLLERS Cortex Controllers For units equipped with Cortex Controllers, there are three identical 32 I/O Cortex Controllers in this system: Cab, Body and Tailgate. Each has a unique program with I/O is shared between the three and the In-Cab display. Each controller is equipped with an LED Status indicator.
  • Page 97 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware PROGRAMMABLE CONTROLLERS (CONTINUED) Cab Controller Typically mounted inside the cab, on a conventional cab this controller will be behind or under the seat. On a cab over engine it will be under the dog house cover. This controller manages most of the unit functionality, this includes: Chassis interface, including J1939 comms Hydraulic Pump Controls Option Configuration...
  • Page 98 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware PROGRAMMABLE CONTROLLERS (CONTINUED) Tailgate Controller Mounted in the upper portion of the tailgate this controller manages circuits local to the tailgate, including: Strobe Lights Work Lights Tailgate controls DPF 5000 Tailgate PT Commercial Tailgate Issued July 2020 Copyright 2020, Heil Environmental Body Controller Hardware...

  • Page 99: Control Fusing

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CONTROL FUSING Control Fuses The 2020 REL control system utilizes two fuses. Fuse #1 (F1) is powered by chassis ignition. Fuse #2 (F2) is battery powered by the cold side of the battery disconnect. Fusing for RP170 Compliant Chassis The below fuse holder is typically located within 8”...
  • Page 100 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CONTROL FUSING (CONTINUED) Fusing for NON RP170 Compliant Chassis Non RP170 chassis uses a Power Relay Module, pictured below, with two build-in 20-amp fuses. This module is typically located near the chassis battery disconnect switch. SOURCE FUSE CIRCUIT...

  • Page 101: Control Area Network

    ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CONTROL AREA NETWORK The control system for the 2020 Rear End Loader has multiple components that communicate over Control Area Networks or CAN. a. In-Cab Display b. Cab Controller (32 I/O Cortex Control Module) c.
  • Page 102 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CONTROL AREA NETWORK (CONTINUED) Network Schematic Issued July 2020 Copyright 2020, Heil Environmental Body Controller Hardware Printed in the U.S.A.
  • Page 103 ® POWERTRAK COMMERCIAL PLUS Body Controller Hardware CONTROL AREA NETWORK (CONTINUED) System Architecture Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Body Controller Hardware...
  • Page 104 ® POWERTRAK COMMERCIAL PLUS NOTES Issued July 2020 Copyright 2020, Heil Environmental Body Controller Software Printed in the U.S.A.
  • Page 105 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE SECTION 6 BODY CONTROLLER SOFTWARE Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Body Controller Software...

  • Page 106: Body Controller Software

    ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE CORTEX CONTROLLER PROGRAM DOCUMENTATION FOR OAI UNITS - PROGRAM 109-0327 Document Scope: This document details the operation and application of program 109-0327. This program is written for controller P/N: 254- 4912 and is utilized in PDC equipped REL units, as a retrofittable replacement for the mini PLC P/N: 108-7860. The primary function of this application is to manage the OIGAI tandem pump control.
  • Page 107 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE Section 2: Program 109-0327 I/O Functions 2.01: I/O Chart PROGRAM: 109-0237 REVISION: 20180814 CONTROLL SIGNAL ADDRESSING ER PINOUT REL– (DP5000 / PT COMM / PT COM PLUS / PT1000) INPUT FUNCTIONS SPARE INPUT IN00 BINARY CALIBRATION SIGNAL #1...
  • Page 108 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE BINARY CHASSIS REVERSE ACTIVE SIGNAL IN13 HIGH BINARY CALIBRATION SIGNAL #2 ACTIVE IN14 HIGH BINARY J1939 500K BAUD RATE ACTIVE IN15 HIGH OUTPUT FUNCTIONS BINARY TRANS TEMP INDICATOR ACTIVE OUT00 HIGH SPARE OUTPUT OUT01 SPARE OUTPUT OUT02...
  • Page 109 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE CHASSIS-J1939 Network (NOT USED) CAN1-L CHASSIS-J1939 Network (NOT USED) CAN1-H POWER SUPPLY VOLTAGE PDC, BOX CONTROLLER VBBS 2, CB-6 SUPPLY VOLTAGE PDC, BOX OUTPUT 00-07 VBB1 2, CB-6 SUPPLY VOLTAGE PDC, BOX OUTPUT 08-15 VBB2 2, CB-2 Copyright 2020, Heil Environmental...
  • Page 110 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE 2.02: Input Functions A01 - Not Assigned (IN00) Spare input. Function Logic: Input Device Status I/O Address Status Spare IN00 A02 - Calibration Signal #1 (IN01) This input is activated by the Configuration Jumper and is used during engine speed calibration. Function Logic: Input Device Status...
  • Page 111 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE A06 - Right Turn Signal (IN05) This input is connected to the left-hand turn signal. The input is ON when the turn lamp is ON. Function Logic: Input Device Status I/O Address Status Chassis L.H.
  • Page 112 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE A11 - Slide Active (IN10) This input is connected to the pump enable circuit downstream of the side door interlock relay. The input should be ON with the Pump switch ON and Side Door closed, if equipped. Function Logic: Input Device Status...
  • Page 113 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE 2.03: Output Functions B01 – Transmission Temp. Indication (OUT00) Activation of this output indicates that the Transmission Sump/Retarder Temperature is high. With this output ON the hydraulic pumps will disable and remain disabled until the transmission temperature warning is OFF three minutes, or ignition power is cycled. Conditions Necessary to activate the circuit: Condition Logic Function or Component...
  • Page 114 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE B05 - Pump Solenoid (P1) (OUT04) This output controls the Pump Solenoid (P1). Pump 1 Operating Speed Parameters Setting Max. Engage Speed 1000 RPM Max. Operate Speed 1000 RPM Conditions Necessary to activate the circuit: Condition Logic Function or Component...
  • Page 115 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE B09 – Not Assigned (OUT08) Spare Output. Conditions Necessary to activate the circuit: Condition Logic Function or Component Status Status none none none none B10 – Not Assigned (OUT09) Spare Output. Conditions Necessary to activate the circuit: Condition Logic Function or Component...
  • Page 116 ® POWERTRAK COMMERCIAL PLUS BODY CONTROLLER SOFTWARE Issued July 2020 Copyright 2020, Heil Environmental Body Controller Software Printed in the U.S.A.

  • Page 117: Schematics

    ® POWERTRAK COMMERCIAL PLUS Schematics SECTION 7 SCHEMATICS Copyright 2020, Heil Environmental Issued July 2020 Printed in the U.S.A. Schematics...

  • Page 118: Harness, Body Controller, 2020 Rel - 263-1869-001

    TANK ANTI PSI#2 PSI#1 FMVSS FMVSS CAN1 CAN1 TWISTED PAIR TWISTED PAIR CAN1 CAN1 CAN1 NO LOOM ON MAIN TRUNK BUNDLE WIRES WITH CABLE TIES ANTI BODY TANK LOWER SOL BODY CONTROL SWITCH RAISE SOL FMVSS FMVSS LOWER SOL EJECTOR RET.

  • Page 119: Harness, Body, 2020 Rel - 263-1869-002

    REF PINOUT 108-8721-005 GROUND CLEAR WHITE SIDE STOP / TURN / STROBE DOOR REF PINOUT 108-8721-004 GROUND WORK BLACK WORK OVAL LIGHT STROBE WHITE TAIL / CLEAR / MARKER STOP / TURN / STROBE STROBE WORK LIGHT STROBE RH MID TURN OVAL STROBE...

  • Page 120: Harness, Mid Tailgate Light Cluster, 2020 Rel - 263-1869-011

    12 8 REF PINOUT 108-8721-005 WHITE REF PINOUT 108-8721-004 BLACK SIDE SIDE WHITE SPARE MECH CAN2 TWISTED PAIR FMVSS UPPER TWISTED PAIR TWISTED PAIR REV -...

  • Page 121: Harness, Upper Tailgate, 2020 Rel - 263-1869-020

    REV -...

  • Page 122: Harness, Cab Controller Convent Cab Non Rp70, 2020 Rel - 263-1882-001

    SPARE INPUTS AND OUTPUTS PUMP D-1A CTRL SA125 CAN-1 CAN1 DISP PUMP TWISTED PAIR CAN1 D1-A D1-A TWISTED PAIR TWISTED PAIR CAN1 REV -...

  • Page 123: Harness, Cab Controller Cab Over Rp170, 2020 Rel - 263-1882-002

    SPARE INPUTS AND OUTPUTS BODY CAN-1 D-1A FUSE 3 CTRL FUSE 4 SA125 PUMP DISP CAN1 PUMP TWISTED PAIR CAN1 BODY TWISTED PAIR TWISTED PAIR CAN1 CHASSIS CHASSIS INTERFACE INTERFACE CONNECTOR CONNECTOR D-1A REV -...

  • Page 129: Index

    ® POWERTRAK COMMERCIAL PLUS INDEX grease lubrication recommendation access cover adjust the lower panel hydraulic detent hazard symbols and definitions adjust the upper panel hydraulic detent hydraulic drive control adjustment of relief valve "B" hydraulic oil specifications air supply kits pneumatic diagrams hydraulic symbols alternator "R"...
  • Page 130 ® POWERTRAK COMMERCIAL PLUS INDEX specifications standard torque data for nuts and bolts standard torque data for nuts and bolts table storing refuse in the body tailgate control valve tailgate control valve pressure settings tailgate lubrication tailgate nomenclature tailgate support props tailgate valve tandem O.I.G.A.I.
  • Page 131 HEIL ENVIRONMENTAL WARRANTY STATEMENT The Heil Co. d/b/a Heil Environmental ("Heil") warrants its solid waste collection equipment to be free from defects in material and workmanship under normal use for a period of one (1) year or 2000 hours of operation (whichever comes first) from the date of equipment In-Service or during the period of coverage offered by an extended warranty program, when proper service and maintenance as described in Heil Service Bulletins and Parts &...
  • Page 132 www.heil.com Customer Care: 866-ASK-HEIL (866-275-4345) Heil Environmental 4301 Gault Avenue North Fort Payne, AL 35967-9984 Parts Central: 800-528-5308 Technical Service: 866-310-4345 TechSupport@DoverESG.com...

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